Size-effects and Surface Integrity in Machining and Their Influence on Product Sustainability

In machining, the specific cutting energy is known to exponentially increase as the uncut chip thickness decreases. This phenomenon has been known as 'size-effect' is also observed by varying the cutting edge radius, especially when this radius is of the same order or greater than the uncut chip thickness. In such conditions, the quality of the machined surface can be significantly affected. In the work presented in this paper, the influence of the cutting edge radius on the quality of the machined surface was evaluated in terms of surface defects, residual stresses and micro-hardness. The paper presents an analysis of relevant experimental results and a modelling approach for controlled residual stresses in machining, all aimed at improving product sustainability, in terms of its resulting lifetime.

[1]  N. Zorev.  Metal cutting mechanics , 1966 .

[2]  Mohamed A. Elbestawi,et al.  Modelling the effects of tool-edge radius on residual stresses when orthogonal cutting AISI 316L , 2007 .

[3]  José Outeiro.  Influence of tool sharpness on the thermal and mechanical phenomena generated during machining operations , 2007 .

[4]  I. S. Jawahir,et al.  On the Effects of Residual Stresses Induced by Coated and Uncoated Cutting Tools with Finite Edge Radii in Turning Operations , 2006 .

[5]  I. Jawahir,et al.  Finite element modeling of residual stresses in machining induced by cutting using a tool with finite edge radius , 2005 .

[6]  I. S. Jawahir,et al.  A new comprehensive methodology for the evaluation of product sustainability at the design and development stage of consumer electronic products , 2009 .

[7]  J. Cohen,et al.  Residual Stress: Measurement by Diffraction and Interpretation , 1987 .

[8]  I. Jawahir,et al.  Size effects in manufacturing of metallic components , 2009 .

[9]  P. Albrecht,et al.  New Developments in the Theory of the Metal-Cutting Process: Part I. The Ploughing Process in Metal Cutting , 1960 .

[10]  W. P. Evans,et al.  Mathematical Correction for Stress in Removed Layers in X-Ray Diffraction Residual Stress Analysis , 1958 .

[11]  I. S. Jawahir,et al.  Product Design for Sustainability: A New Assessment Methodology and Case Studies , 2007 .

[12]  Taylan Altan,et al.  A finite element analysis of orthogonal machining using different tool edge geometries , 2004 .

[13]  I. S. Jawahir,et al.  Development of a Sustainability Scoring Method for Manufactured Automotive Products: A Case Study of Auto Body Panels , 2007 .

[14]  William J. Endres,et al.  A New Model and Analysis of Orthogonal Machining With an Edge-Radiused Tool , 2000 .